The most modern printing house in Russia
On the outskirts of Tver operates the most modern Russian book typography.
Typography for me, spent twenty years in print design, sweet home and it was very interesting to compare what we had before, and as it looks now in Europe that was built from scratch two years ago near Tver.
I must say that this level of printing production equipment and the organization of work in Russia, I have not seen.
"Pareto-Print" - a specially designed and constructed building of several huge, well-lit, clean room, divided into zones: pre-press production, printing, bookbinding production, finishing, finished goods warehouse and office center. Only 600 people work here, of which 460 are directly engaged in the production of multi-shift operation.
I'm just envious of how powerfully equipped in the printing press. Pressroom is equipped with seven most modern offset printing machine ManRoland different series. In my time on so many of these magnificent machines in one place and not have to dream. And then one vosmisektsionny "Roland" is worth something!
The remote control sheet-fed offset printing machine - a system of online check print quality. The printer using the densitometer controls the ink density on the scales deposited on the edge of the recording sheet. And here also controls the flow of paint on the computer monitor.
Printers to the printer recruited local - the benefit that in Tver with its multiple printing plant was always a good selection of experts. I spoke with a few - a very smart guys, so good explain the show.
On the left, near the wall - the only domestic equipment in the printing three web presses from Rybinsk - "The Book." As they say, very good. They printed text strip small books. In the center - two cars, in which the role of the paper is cut by sheetfed format. Here, incidentally, the maximum size of the recording sheet 1020h1420 mm.
To the smokers did not lose time and have not been ill, running out into the street, for them to make a special booth, both in airports.
I know a stranger, this picture is not enough, what he would say, and I just genuinely happy, looking at such wealth and such a procedure. I used to like we have not seen. I used to put a good technique in the old wall and looked it all somehow. And here, when everything is made from scratch and with great intelligence, according to the rules, the feeling is quite another. The boys said that work in such conditions is bad, somehow - a shame.
Pleasure to see.
Bookbindery always takes a lot of space, especially when printed "thick" sections of the book and for the selection of sheets a lot. There is also a fully automatic line hardcover, which are collected in a single pass binding cover all personal belongings, like a bookend, gauze and captan, and then inserted into her book block. There is a line of clothing and up Perfect binding, there are several folding machines (folding) sheets, excellent cutting machine "Polar" - for me the most interesting part of the whole process of finishing. In short, there is everything, even automatic packing books into piles and stacking on pallets. Everything is in the best European printing houses.
The average salary - 33 000 rubles. On average in the Tver region, as I said, 17 000.
This crosslinked book block.
This is a binding cover.
In the car, it all turns into a finished book.
And then books like this pack and send to the customer.
Here is folded booklets.
Cutting machine - the most important part of the whole process. They are now all with the programming, it is difficult to make a mistake and cut sheets are not. The most impressive when the knife cut foot, one instantaneous movement. I love the sound and ready to stand next to the cutter as you like, looking at how it works. Process r. N. jogging (ie. e. alignment of sheets in a stack) has long been an automatic (on the vibrating table), but earlier by the carver required special skill to knock the stack by hand, such special hand movements. I tried many times to learn it - so something and did not work well.
The entire printing press is equipped with a single system of removing scraps of paper - this is such overarching thing I have to be honest, I saw live only in the "Pareto-Print". Every workplace (like a cutter, for example - you can see it right a rectangular socket) installed "vacuum cleaners" which fly all trim paper and cardboard. All this is going in the same place, where there is a huge press. Waste is compacted and transported for processing.
The basis of any offset printing - a printing plate. For each of the four colors (CMYK) is its own. Previously, to produce a printing plate, it was first necessary to bring the work on the film using RIP (Raster Image Processor), then to copy the frame to move with the film image on the printing plate. Several years ago, the process simplified, abandoning the intermediate film manufacturing process. There was CtP technology (Computer-to-Plate), by which the work laser printed on to the film and directly on the printing plate. At first, technology was damp, there were problems with the materials, but now firmly won CtP prepress market and in modern printing presses are here such laser printing device with online film development, which are ready printing plates directly from the computer.
That's because developing machine leaves the finished printing plate for offset printing. Here are Kodak CtP devices company that since 2005, bought the Canadian manufacturer of the Creo devices, lets them now under its own brand.
plates installation process is automated in modern presses.
In the logistics department told me that on this rack are publications issued in one month. Capacity of the entire printing press is impressive - 69 million books and booklets in the year. This is about 8% of the total book market in Russia.
To match the circulation and storage of finished products.
All office brought the whole of Germany.
in the production I'm always show me the dining room.
A full three-course meal with a compote employee costs 40 rubles. On the stand into the dining room hangs a reminder that on Saturday, two buses driven by employees in the Moscow theater.
Books! Here you can get stuck for a long time. What is just not print. From giant reproductions of albums to tiny Bibles bound in genuine leather. From annual reports to the punching of the cover and selective varnish on the text to popular literature. There is even a section of gilt edge books - it's very time-consuming work, which used to have in the country did not do.
The famous album "Russia through the train window" with magnificent scenery on the spreads are printed here.